JP2013016087A - Parts management device and parts management method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a parts management device capable of increasing productivity by instructing workers appropriate flow of parts to a production line.SOLUTION: In a parts management device 10, a storage 130 stores: production scheduling information including plural production schedules and line information for identifying a parts group including plural parts used in a production schedule; line excess parts number information including information representing remaining parts which remain within the parts group identified by the line information; and parts constitution information including information representing parts to be used in production of a printed board in each production schedule. The parts management device 10 includes a line setting section 103 for establishing line information used in a new schedule by using sharing ratio between remaining parts for each line information represented by the information included in the line excess parts number information after implementing the production schedule to which the line information is established, and parts to be used represented by the information included in the parts constitution information in a new schedule which is a production schedule to which line information is not established.

Description

  The present invention relates to a component management device and a component management method for managing components mounted on a printed circuit board, and more particularly to a component management device and a component management for managing components supplied to a production line according to production plans for various printed circuit boards. It is about the method.

  In recent years, the component mounting apparatus has shifted from a rotary system in which a conventional component placement unit operates to a modular system in which the component placement unit is fixed. The component arrangement part of the modularized component mounting apparatus has a cart structure, and has a function capable of exchanging a wide variety of components in units of carts. In addition, as functions are advanced, a single component mounting apparatus can cope with a wide variety of components. A component management device that manages components supplied to the component placement unit of the component mounting device has been proposed (see, for example, Patent Document 1).

  Here, the component management apparatus specifies the product number and the number of each component mounted on the printed circuit board to be produced. Then, the quantity of each part necessary for producing the number of printed circuit boards to be produced is specified from the part number and the number of parts specified. Then, in addition to the parts supplied from the cassette installed in the production line, it is determined whether or not the quantity of each specified part can be ensured including parts stored in the warehouse. As a result of the determination, if the quantity of each specified part can be secured, a list of the location of each part is created in reel units. On the other hand, if the specified quantity of each part cannot be secured, a list of parts that could not be secured is created.

  In this way, the parts management apparatus diverts the parts supplied from the cassette installed on the production line.

JP 2002-182731 A

  Here, the part replacement time from the previous model to the next model occupies a large proportion of the model switching time. In order to shorten model switching time and increase equipment productivity, it is necessary to shorten part replacement time.

  There are two main types of parts replacement methods. The first (replacement method 1) is a method in which common parts used in the next model among the parts used in the previous model are diverted from the previous model and only the parts used only in the next model are issued from the warehouse. . In particular, for parts that are commonly used in multiple models, the parts replacement time has been shortened by setting the same component placement position (array) in the multiple models.

  The other (replacement method 2) is a method in which the parts of the next model are all set up during production of the previous model, and the parts are replaced by batch replacement after the completion of production of the previous model. All parts of the previous model that were exchanged in bulk will be returned to the warehouse. This external setup method requires a shorter part replacement time than the previously described method. However, as part preparation, it is necessary to prepare all parts for both the previous model and the next model as well as the dedicated parts for the next model. This increases the man-hours for preparing parts.

  Therefore, in the case of the next model in which the parts from the previous model are frequently used, the parts are generally replaced by the replacement method 1, and when there are few parts to be reused, the parts are generally replaced by the replacement method 2.

  In the conventional parts management apparatus, is the replacement method 1 (setting to divert the parts supplied from the cassette installed in the production line)? Each operation can be realized by switching whether or not the exchange method 2 (setting not to be diverted) is taken.

  However, for example, if there are many parts that are reused from the previous model, if you replace the previous model and the next model in a batch, and replace the next model and the next model in a batch, return the previous model parts to the warehouse immediately. Further, it is necessary to take out parts for the next model from the warehouse, and there is a problem that useless man-hours are used for supplying parts.

  The present invention solves the above-described conventional problems, and provides a parts management apparatus and a parts management method capable of improving productivity by instructing an operator to appropriately move parts to a production line. The purpose is to provide.

  In order to achieve the above object, a component management apparatus according to one aspect of the present invention is a component that is supplied to a production line using information stored in a storage unit in accordance with a production plan for producing a printed circuit board. The storage unit is a plurality of the production plans and information determined for each of the production plans, and includes a plurality of the parts used in the production plans. Production plan information including system information that is information for identifying a part group, and a remaining part that indicates a remaining part that is a part remaining in the part group identified by the system information after execution of the production plan for each of the system information Stores line excess part number information including part information and part configuration information including used part information indicating used parts that are parts used for production of the printed circuit board for each production plan. The parts management device includes the system information indicated by the remaining part information included in the line excess part number information after execution of the production plan in which system information is determined among the plurality of production plans included in the production plan information. Sharing indicating the degree of common between the remaining parts for each and the used parts indicated by the used part information included in the part configuration information in the new plan that is a production plan in which system information is not defined among the plurality of production plans The system setting part which determines the system | strain information which shows the components group used by the said new plan using a rate is provided.

  According to this, the parts management apparatus uses the sharing ratio between the remaining parts for each system information after the execution of the production plan for which system information is defined and the used parts in the new plan for which system information is not defined. Determine the grid information in the new plan. Here, the system information is information for identifying a part group composed of a plurality of parts used in the production plan, and the remaining number at the end of production of the parts used for production on the production line is used for the next production. This is information indicating the flow to be taken over. As described above, by managing the parts of the production line for each flow (system), it is possible to use the remaining production parts of the previous model even with respect to the discontinuous printed circuit board models. In other words, the remaining parts on site can be stored separately for each system, and when a new production plan is executed, a system that can shorten the time for collecting parts can be selected and the remaining parts can be used. If the next model has a high degree of diversion with the current production system, the model change is completed by exchanging only a small difference, and the next model is the current production model with the diversion. If it is low, the external setup using the remaining material of another system with high diversion can be carried out during the production of the current production model. In this way, by instructing the worker to appropriately move the parts to the production line, it is possible to realize both improvement in productivity by shortening the part supply time and shortening the model switching time.

  Preferably, the storage unit further stores stock information including line stock part information indicating a line stock part that is a part stocked on the production line and the number of the line stock parts. And the production plan information further including the type of the printed circuit board produced in the production plan and the number of the printed circuit boards, and the line excess part number information further including the number of the remaining parts for each remaining part; And storing the component configuration information further including information indicating the used components for each type of the printed circuit board as the used component information and information indicating the number of used components, the system setting unit The number of used parts used in the production plan in which the system information is determined is calculated using the production plan information and the part configuration information, and the used part is calculated. And the inventory information to calculate the number of remaining parts after execution of the production plan in which the system information is determined to create the line excess parts number information, and the created line excess parts The system information indicating the parts group used in the new plan is determined using the numerical information.

  According to this, the system setting unit uses the production plan information, the part configuration information, and the inventory information to create the line excess part number information after the execution of the production plan in which the system information is determined, The system information in the new plan is determined using the number-of-parts information. For this reason, the parts management device can determine the system information in the new plan by using the information stored in the storage unit, and uses the determined system information to determine the part information for the production line. Productivity can be improved by instructing appropriate movement to the worker.

  Preferably, the storage unit further stores picking information including warehouse part information indicating a warehouse part which is a part existing in a warehouse, and system information indicating a group of parts supplying the warehouse part. The parts management device further includes a material allocation calculation unit that creates the picking information for picking a new part from the warehouse that is a part used in the new plan for which the system setting unit has determined system information. The material allocation calculation unit calculates new part information, which is information indicating the new part, using the production plan information and the part configuration information in the new plan, and calculates the new part information and the production From the warehouse to the production line using the remaining part information in the system information in the new plan, which is included in the line excess part number information after execution of the plan When picking part information indicating picking parts that are parts to be supplied is calculated, and the number of picking parts indicated by the picking part information is greater than the number of warehouse parts, the shortage information is output and the picking part information When the number is equal to or less than the number of warehouse parts, the picking information is created by adding the same system information as the system information in the new plan to the warehouse part information indicating the warehouse part.

  According to this, the material allocation calculation unit calculates the picking part information indicating the picking part by using the production plan information, the part configuration information, and the line excess part number information in the new plan, and calculates the number of picking parts and the warehouse parts. And picking information in which the system information is added to the warehouse part information. In this way, the component management apparatus can create picking information to which system information is assigned by using information stored in the storage unit, and instructs the worker to pick using the created picking information. can do. For this reason, productivity can be improved by instruct | indicating to a worker the appropriate movement of components with respect to a production line.

  Preferably, the storage unit further stores inventory information including warehouse part information indicating a warehouse part which is a part existing in a warehouse, and system information indicating a group of parts supplying the warehouse part. The parts management device further includes warehouse parts information indicating the predetermined warehouse parts based on picking results performed according to the picking information for supplying the predetermined warehouse parts to the parts group indicated by the predetermined system information. And a picking unit for creating the inventory information to which the same system information as the predetermined system information is assigned.

  According to this, the parts management device creates inventory information in which predetermined system information is added to warehouse part information indicating a predetermined warehouse part based on the picking record. Thereby, inventory information can be managed for every system | strain, and productivity can be improved by instruct | indicating an operator to the appropriate movement of components with respect to a production line using the said inventory information.

  Note that the present invention can be realized not only as such a component management apparatus, but also as a component management method including steps characteristic processing performed by the processing unit included in the component management apparatus. . Further, it can be realized as a program or an integrated circuit for causing a computer to execute characteristic processing included in the component management method. Needless to say, such a program can be distributed via a recording medium such as a CD-ROM and a transmission medium such as the Internet.

  According to the component management apparatus according to the present invention, it is possible to improve productivity by instructing an operator to appropriately move components to the production line.

It is a block diagram which shows the function structure of the components management apparatus in embodiment of this invention. It is a figure which shows an example of the components information master in embodiment of this invention. It is a figure which shows an example of the components structure master in embodiment of this invention. It is a figure which shows an example of the production plan information in embodiment of this invention. It is a figure which shows an example of the inventory information in embodiment of this invention. It is a figure which shows an example of the line excess component number information in embodiment of this invention. It is a figure which shows an example of the picking information in embodiment of this invention. It is a flowchart which shows an example of the process which the components management apparatus in embodiment of this invention performs. It is a flowchart which shows an example of the process in which the system | strain setting part in embodiment of this invention sets the system | strain of a new plan. It is a figure for demonstrating the process in which the system | strain setting part in embodiment of this invention sets the system | strain of a new plan. It is a figure for demonstrating the process in which the system | strain setting part in embodiment of this invention sets the system | strain of a new plan. It is a figure for demonstrating the process in which the system | strain setting part in embodiment of this invention sets the system | strain of a new plan. It is a figure for demonstrating the process in which the system | strain setting part in embodiment of this invention sets the system | strain of a new plan. It is a flowchart which shows an example of the process of material allocation calculation and picking information preparation which the material allocation calculation part in embodiment of this invention performs. It is a flowchart which shows an example of the process which the picking part in embodiment of this invention performs a picking operation | work.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

<About the overall configuration>
FIG. 1 is a block diagram showing a functional configuration of a component management apparatus 10 according to an embodiment of the present invention.

  As shown in the figure, the parts management apparatus 10 acquires production plan information from the production plan creation apparatus 110 and also acquires production result information from the production result collection apparatus 120 to produce a production plan for producing various printed circuit boards. It is a device that manages the parts supplied to the production line accordingly.

  Here, the production plan creation device 110 is, for example, a scheduling system, and creates production plan information that is information indicating a production plan such as a production order for each production line. Further, the production performance collection device 120 is, for example, a MES (Manufacturing Execution System) and collects production performance information that is information indicating the production performance for each production line.

  The component management apparatus 10 is configured by a computer, for example, and includes a material management unit 100 and a storage unit 130. The material management unit 100 includes a production plan input unit 101, a picking information creation unit 102, an inventory input unit 105, a picking unit 106, a production result input / material consumption calculation unit 107, a return calculation unit 108, and a master input unit 109. ing. The storage unit 130 is a memory that stores a part information master 131, a part configuration master 132, production plan information 133, inventory information 134, line excess part number information 135, and picking information 136.

  The production plan input unit 101 inputs the production plan information created by the production plan creation device 110 and registers the acquired production plan information in the production plan information 133 of the storage unit 130.

  The picking information creation unit 102 includes a system setting unit 103 and a material allocation calculation unit 104.

  The system setting unit 103 sets a system for a new plan. Specifically, the system setting unit 103 updates the production plan information 133 in the storage unit 130 by determining a system number that is the system number of the new plan and writing the determined system number in the storage unit 130.

  Here, the system is a flow of taking over the remaining number at the end of production of parts used for production on the production line to the next production. That is, at the time of calculating the picking material of the next plan, the remaining parts and the remaining number of the production completion plan having the same system number are allocated, and the calculation is made so that the shortage is delivered from the warehouse. When there is no same system number, it will be calculated to leave all from the warehouse.

  The material allocation calculation unit 104 refers to the production plan information 133 stored in the storage unit 130, determines necessary parts and their quantities, parts to be picked from the warehouse and their quantities, and determines the determined parts and their The quantity is registered in the picking information 136 of the storage unit 130.

  The inventory input unit 105 inputs, for example, the part number and the remaining number of parts newly received in the warehouse via a computer screen, and registers the input information in the inventory information 134 of the storage unit 130. To do.

  The picking unit 106 is a processing unit that assists an operator in actually picking parts from a warehouse. The picking unit 106 refers to the picking information 136 stored in the storage unit 130 to perform the support, and updates and registers the inventory information 134 and the picking information 136 in the storage unit 130 every time picking is performed by the worker. To do.

  The production result input / material consumption calculation unit 107 inputs the production result information collected by the production result collection device 120 when the production progresses based on the picked parts, and calculates the consumed parts and the quantity thereof. The production plan information 133, inventory information 134, and picking information 136 in the storage unit 130 are updated.

  The return storage calculation unit 108 is a processing unit that calculates an unnecessary part on the production line after the production is completed, and registers that the unnecessary part is returned to the warehouse. The inventory information 134 in the storage unit 130 is registered. Update.

  The master input unit 109 inputs the component information and the component configuration information of the printed circuit board from, for example, a computer screen, and registers the input information in the component information master 131 and the component configuration master 132 of the storage unit 130.

  Next, the part information master 131, the part configuration master 132, the production plan information 133, the inventory information 134, the line excess part number information 135, and the picking information 136 stored in the storage unit 130 will be described in detail.

<Part information master 131>
FIG. 2 is a diagram showing an example of the component information master 131 in the embodiment of the present invention.

  The component information master 131 is a collection of data indicating component information. Here, the component information is information related to components mounted on the printed circuit board, and the component information master 131 includes information indicating the component product number, the component name, the shelf number, the number of packages, the manufacturer name, the pitch, and the width. . The information is registered for each part number.

  Here, the part product number is a number unique to the part, and is a name of used part information indicating a used part which is a part used for production of a printed circuit board. The part name is a name that can identify the type of the part. The storage bin is information indicating a place in the warehouse. The number of packages is the number of parts that are newly purchased. The manufacturer name is the company name of the manufacturer. The pitch is an interval at which the components are sealed when the components are reel-shaped components. The width is the width of the reel.

<Parts configuration master 132>
FIG. 3 is a diagram showing an example of the component configuration master 132 in the embodiment of the present invention.

  The component configuration master 132 is a collection of data indicating the component configuration information. Here, the part configuration information is information on the part number and the number of parts necessary for producing the printed circuit board, and the used part information indicating the used parts which are parts used for the production of the printed circuit board for each production plan. Including. That is, the component configuration information includes information indicating the used components for each type of printed circuit board as the used component information and information indicating the number of used components.

  Specifically, the part configuration master 132 includes information indicating the model, plane, Ver, line, equipment, lane, part product number, and number. The information is registered for each model, plane, Ver, line, facility, and lane.

  Here, the model is a number unique to the printed circuit board to be produced and is a designation. The surface is information for discriminating between the front surface and the back surface of the model. Ver is version information for discriminating a difference in the part number and the number in accordance with the revision of the part configuration. A line is a production line. Equipment refers to production equipment. A lane is a feeder number of the equipment. The part product number is a part-specific number, that is, used part information indicating a used part that is a part used for production of a printed board for each type of printed board, and is associated with the part number of the part information master 131. The number is the number of parts used in the production of the model in the line.

<Production plan information 133>
FIG. 4 is a diagram showing an example of the production plan information 133 in the embodiment of the present invention.

  The production plan information 133 is a collection of data indicating production plan information. Here, the production plan information is information indicating when and on which production line the printed circuit board is produced, and is information determined for each production plan and each production plan, and is used in the production plan. It includes system information that is information for identifying a component group composed of a plurality of components, the type of printed circuit board produced in the production plan, and the number of the printed circuit boards.

  Specifically, the production plan information 133 includes information indicating the lot number, line, system, model, surface, Ver, production date, planned number, start time, and status. The information is registered for each lot number. In addition, production plan information is registered for each system in the same line.

  Here, the lot number is a unique number indicating a production plan, and is a number determined by the production plan creation device 110 or the production plan input unit 101. Line is the name of the line scheduled to be produced. The system indicates system information, and is information for discriminating a series of production plans that take over the number of excess line parts. The model is a number unique to the printed circuit board to be produced and is associated with the model of the component configuration master 132. The surface is information for discriminating between the front surface and the back surface of the model. Ver is version information for discriminating a difference in the part number and the number in accordance with the revision of the part configuration. The production date is a scheduled date for production in the model, plane, and Ver. The planned number is the number to be produced. The start time is a scheduled production start time. The state is information necessary for the material management unit 100 to manage the plan. For each lot number, any of unallocated, allocated, picking, picking completion, production, and production completion is registered. .

<Inventory information 134>
FIG. 5 is a diagram showing an example of the inventory information 134 in the embodiment of the present invention.

  The inventory information 134 is a collection of data indicating inventory information. Here, the inventory information is information indicating the part number and the remaining number of parts existing in the warehouse or the production line. The line inventory part information indicating the line inventory parts which are parts in stock on the production line, and the line inventory parts. , Warehouse part information indicating a warehouse part that is a part existing in the warehouse, and system information indicating a part group for supplying the part.

  Specifically, the stock information 134 includes information indicating a reel ID, a part number, a remaining number, a location, a line, equipment, a system, a date of receipt, an initial quantity, and a state. Further, this information is registered for each reel ID. In addition, inventory information is registered for each system even on the same line.

  Here, the reel ID is information unique to each component and is a number determined by the inventory input unit 105. The part product number is a part-specific number and indicates line inventory part information and warehouse part information. The remaining number is the remaining number of parts for each reel ID. The location is information indicating whether the location where the part exists is a production line or a warehouse. The line is information indicating which production line is located when the part is located on the production line. The equipment is information indicating in which equipment the part is present when the part is located on the production line. The system indicates system information, and is information for discriminating a series of production plans that take over the number of excess line parts. The warehousing date is the date when the parts are warehousing. The initial quantity is the quantity of parts at the time of warehouse receipt. The state is information necessary for the material management unit 100 to manage inventory, and any of unallocated, allocated, and picking completed is registered for each reel ID.

<Excess line number information 135>
FIG. 6 is a diagram showing an example of the line excess component number information 135 in the embodiment of the present invention.

  The line excess part number information 135 is a collection of data indicating the line excess part number information. Here, the excess line parts count information is information that predicts the remaining number of parts when all the production plans allocated on the production line are completed, and is the system information after execution of the production plan for each system information. It includes remaining part information indicating a remaining part that is a part remaining in the identified part group, and the number of remaining parts for each remaining part.

  Specifically, the line excess part number information 135 includes information indicating a line, equipment, system, part number, and remainder. The information is registered for each line, facility, system, and part number.

  Here, the line is information indicating a line to be produced. The facility is information indicating the facility to be produced. The system indicates system information, and is information for discriminating a series of production plans that take over the number of excess line parts. The part product number is a part-specific number and indicates remaining part information. The remaining number is information that predicts the remaining number of parts at the time when production of all the production plans allocated on the production line is completed for each line, facility, system, and part number.

<Picking information 136>
FIG. 7 is a diagram showing an example of the picking information 136 according to the embodiment of the present invention.

  The picking information 136 is a collection of data indicating picking information. Here, the picking information is information on parts scheduled to be delivered from the warehouse to the production line, warehouse part information indicating warehouse parts that are parts existing in the warehouse, system information indicating a part group supplying the warehouse parts, and including.

  Specifically, the picking information 136 includes information indicating picking NO, line, system, equipment, part number, reel ID, remaining number, shelf number, lot number, and picking state.

  Here, picking NO is a unit of picking. The line is information indicating a line to be produced. The facility is information indicating the facility to be produced. The system indicates system information, and is information for discriminating a series of production plans that take over the number of excess line parts. The part product number is a part-specific number and indicates warehouse part information. The reel ID is a reel ID scheduled to be picked. The remaining number is the remaining number of parts scheduled to be picked. The shelf number is information indicating the position of the shelf in which the reel to be picked is stored. The lot number is a unique number indicating a production plan, and indicates which production plan the picking information is. The picking state represents the progress of picking, information on the picking schedule is unworked, and information on completion of picking is finished.

<Overall process>
Next, a series of processes according to the present invention will be described based on the flowchart of FIG. FIG. 8 is a flowchart illustrating an example of processing performed by the component management apparatus 10 according to the embodiment of the present invention.

  As shown in the figure, first, the production plan input unit 101 of the material management unit 100 inputs production plan information from the production plan creation device 110 and the like, and the input production plan information is converted into production plan information in the storage unit 130. It memorize | stores in 133 (S101). As a result, the production plan information 133 shown in FIG. 4 registers information about how many printed circuit boards are produced on which production line, the scheduled production start date, and the production start time. In addition, system information is registered in the production plan information 133.

  Then, the inventory input unit 105 of the material management unit 100 inputs the inventory information, and stores the input inventory information in the inventory information 134 of the storage unit 130 (S102). As a result, information such as the part number and the remaining number of parts is registered for each part-specific reel ID in the inventory information 134 shown in FIG. In addition, system information is registered in the inventory information 134.

  Then, the system setting unit 103 of the material management unit 100 sets a new plan system for each production line (S103).

  Specifically, the system setting unit 103 is indicated by the remaining part information included in the line excess part number information after execution of the production plan in which the system information is determined among the plurality of production plans included in the production plan information. Share rate indicating the degree of commonality between the remaining parts for each system information and the used parts indicated by the used parts information included in the part configuration information in the new plan that is a production plan for which system information is not defined among multiple production plans Is used to determine system information indicating a part group used in the new plan. The details of the process in which the system setting unit 103 sets the system of the new plan will be described later.

  Then, the material allocation calculation unit 104 of the material management unit 100 determines whether or not there is an inventory of parts necessary for the production of the new plan, creates the inventory information of the inventory of the existing parts, and stores it in the picking information 136. Store (S104).

  That is, the material allocation calculation unit 104 creates picking information for picking a new part, which is a part used in the new plan for which the system setting unit 103 has determined the system information, from the warehouse. Details of the material allocation calculation and picking information creation processing performed by the material allocation calculation unit 104 will be described later.

  Then, the material management unit 100 determines whether or not the above processing (S103, S104) has been performed in all production lines (S105). When the material management unit 100 determines that it has been implemented in all production lines (Y in S105), the material management unit 100 proceeds to the next process, and when it is determined that it has not been implemented in all production lines (in S105). N) The above processing (S103, S104) is performed again.

  Next, the picking unit 106 of the material management unit 100 performs a picking operation for each production line (S106).

  Specifically, the picking unit 106 indicates a warehouse part indicating the predetermined warehouse part based on the picking result performed according to the picking information for supplying the predetermined warehouse part to the part group indicated by the predetermined system information. Inventory information in which the same system information as the predetermined system information is added to the information is created. The details of the process in which the picking unit 106 performs the picking operation will be described later.

  And the material management part 100 judges whether it implemented in all the production lines (S107). If the material management unit 100 determines that it has been implemented in all production lines (Y in S107), the material management unit 100 proceeds to the next process, and if it is determined that it has not been implemented in all production lines (in S107). N) The above processing (S106) is performed again.

  Next, the production result input / material consumption calculation unit 107 of the material management unit 100 inputs the production result for each production line, and subtracts the remaining number of parts based on the input (S108).

  And the material management part 100 judges whether it implemented in all the production lines (S109). If the material management unit 100 determines that it has been implemented in all production lines (Y in S109), the material management unit 100 proceeds to the next process, and if it is determined that it has not been implemented in all production lines (in S109). N) The above processing (S108) is performed again.

  Next, the return calculation part 108 of the material management part 100 returns goods for every production line (S110). Note that the return storage calculation unit 108 is performed arbitrarily by an operator who operates the material management unit 100. The return calculation unit 108 calculates parts unnecessary for the current plan for each system. The worker moves parts from the production line to the warehouse based on the calculation result.

  And the material management part 100 judges whether it implemented in all the production lines (S111). If the material management unit 100 determines that it has been implemented in all production lines (Y in S111), the material management unit 100 proceeds to the next process, and if it is determined that it has not been implemented in all production lines (in S111). N) The above process (S110) is performed again.

  Thus, the process performed by the component management apparatus 10 ends.

  Next, the three processes as points will be described below.

<About new plan system setting (S103 in FIG. 8)>
Of the series of processes according to the present invention, details of the new plan system setting (S103 in FIG. 8) will be described based on the flowchart in FIG. FIG. 9 is a flowchart illustrating an example of a process in which the system setting unit 103 according to the embodiment of the present invention sets a new plan system.

  As shown in the figure, the system setting unit 103 receives an instruction to start system setting for a new plan (S121). That is, the operator who operates the material management unit 100 confirms the new plan input by the production plan input unit 101 and designates a new plan to set the system, thereby giving an instruction to start setting the system of the new plan.

  Then, the system setting unit 103 acquires the part configuration master 132, the production plan information 133, and the inventory information 134, creates line excess part number information, and updates the line excess part number information 135 (S122).

  Specifically, the system setting unit 103 acquires an allocated production plan from the production plan information 133 stored in the storage unit 130. In addition, the system setting unit 103 acquires the part configuration of the model of the reserved production plan from the part configuration master 132 stored in the storage unit 130. Further, the system setting unit 103 acquires inventory information for all the acquired components from the inventory information 134 stored in the storage unit 130. Then, the system setting unit 103 creates line excess component number information from the acquired information and registers it in the line excess component number information 135 of the storage unit 130 shown in FIG.

  Here, as a method for calculating the number of excessive line parts included in the excessive line part number information 135, the system setting unit 103 multiplies the number of parts for each part number in the part configuration master 132 by the planned number of production plan information 133. Calculate the production requirement for the allocated plan. That is, the system setting unit 103 manages the necessary number for each production line / system / part part number by linking and managing each system in the production plan. Next, the system setting unit 103 calculates the number of inventory for each production line / system / part number from the inventory information included in the inventory information 134. Then, for each production line / system / part part number, the system setting unit 103 creates line excess part number information by assuming that the quantity obtained by subtracting the necessary number from the above inventory number is the number of excess line parts. Information 135 is updated.

  And the system | strain setting part 103 determines a common part, calculates a sharing rate, and determines the system | strain of a new plan using the said sharing rate (S123).

  Specifically, the system setting unit 103 acquires a new plan for setting the system specified by the operator from the production plan information 133 stored in the storage unit 130. And the system | strain setting part 103 acquires the part structure of the model of the new plan to set the said system | system | group from the components structure master 132 memorize | stored in the memory | storage part 130. FIG. Then, the system setting unit 103 compares the part number of the line excess part number information included in the latest line excess part number information 135 with the part number of the part configuration of the new plan, and the part of the part number that exists in both Is determined as a common part.

  Then, the system setting unit 103 calculates a sharing rate for each production line / system using a value obtained by dividing the number of types of common parts by the number of types of parts of the part configuration of the new plan as a sharing rate. Then, the system setting unit 103 selects a production line / system having the highest sharing rate that is equal to or higher than the previously determined system determination setting value and registers it as a new plan system in the production plan information 133. . The system setting unit 103 registers a system by generating a new system number if the calculated sharing rate is smaller than the system determination set value in any production line / system.

<Example of system setting>
Hereinafter, an example of processing in which the system setting unit 103 sets the system of the new plan will be described.

  FIG. 10A to FIG. 10D are diagrams for explaining a process in which the system setting unit 103 according to the embodiment of the present invention sets a system of a new plan. Specifically, FIG. 10A is a diagram illustrating an example of part configuration information included in the component configuration master 132, and FIG. 10B is a diagram illustrating an example of production plan information included in the production plan information 133. 10C is a diagram illustrating an example of inventory information included in the inventory information 134, and FIG. 10D is a diagram illustrating an example of line excess component number information included in the line excess component number information 135. In the following description, it is assumed that a system determination setting value that is a threshold for determining a system for a new plan is 0.5.

  The system setting unit 103 obtains the model and the planned number of the allocated plan from the production plan information included in the production plan information 133 in order to calculate the excess line component number information included in the line excess component number information 135. To do. According to the example of the production plan information 133 shown in FIG. P0001, P0002, and P0003 correspond to the allocated plan.

  Then, the system setting unit 103 acquires the part configuration of the allocated model from the part configuration information included in the part configuration master 132, and calculates the necessary number of production of each part by the number of each part × the planned number of parts. To do.

  For example, since the allocated plan P0001 is the model AAA and the planned number of 3000, the required number of parts is 3000 for the part number a, 3000 for the part b, 3000 for the part c, 3000 for the part d, and 3000 for the part e. Similarly, the system setting unit 103 similarly calculates the allocated plans P0002 and P0003.

  Next, for each part, the system setting unit 103 calculates the number of excess line parts by subtracting the required production number from the inventory information included in the inventory information 134. For example, in the part number a, the required number of production is 3000 for the model AAA and 3000 for the model CCC, so the total required number is 6000, and the part number a is 10,000 in the inventory information. The number of excess parts is 4000. Similarly, the system setting unit 103 calculates the number of excessive line parts for all parts.

  When the new plan is DDD, the system setting unit 103 refers to the part configuration master 132 and the line excess parts number information 135, and the number of common parts between the system 1 of the line excess parts number and the new plan DDD is a, It is calculated that there are four components b, d, and x, and the sharing rate is 4/5 = 0.8. Moreover, the system | strain setting part 103 calculates that the number of common parts of the system | strain 2 and the new plan DDD is 1 part of q, and a sharing rate is 1/5 = 0.2. In this case, the system setting unit 103 determines that the system 1 of the new plan DDD is 1 because the system 1 has the highest sharing ratio of 0.8 and is equal to or greater than the system determination set value.

  If the new plan is EEE, the system setting unit 103 has two parts, a and b, in the system 1 of the line excess parts number and the new plan EEE, and the sharing rate is 2/5 = 0. 4. The common part number of the system 2 and the new plan EEE is one part of r, and the sharing rate is calculated as 1/5 = 0.2. In this case, the system setting unit 103 determines that the system 1 of the new plan EEE is not 1 or 2 but a new system number 3 because the system 1 has the highest sharing rate of 0.4 but is below the system determination set value. To do.

  As described above, the system setting unit 103 uses the production plan information and the component configuration information to calculate the number of used parts used in the production plan in which the system information is determined, and the calculated number of used parts. And the inventory information are used to calculate the number of remaining parts after the execution of the production plan in which the system information is determined, and to create line excess parts number information.

  And the system | strain setting part 103 is for every system | strain information shown by the remaining parts information contained in the line excess parts number information after execution of the production plan in which system | strain information is defined among several production plans contained in production plan information. A share rate that indicates the degree of commonality between the remaining parts and the used parts indicated by the used part information included in the part configuration information in the new plan that is a production plan in which system information is not defined among a plurality of production plans System information indicating a group of parts used in the new plan is determined.

<About material allocation calculation / picking information creation (S104 in FIG. 8)>
Next, details of material allocation calculation and picking information creation (S104 in FIG. 8) in a series of processes according to the present invention will be described based on the flowchart in FIG. FIG. 11 is a flowchart showing an example of a material allocation calculation and picking information creation process performed by the material allocation calculation unit 104 according to the embodiment of the present invention.

  As shown in the figure, the material allocation calculation unit 104 receives an instruction to start material allocation calculation (S141). That is, the operator who operates the material management unit 100 confirms the system of the unallocated new plan determined in S103 of FIG. 8, and starts the allocation process.

  Then, the material allocation calculation unit 104 acquires the part configuration master 132, the production plan information 133, and the inventory information 134, creates line excess part number information, and updates the line excess part number information 135 (S142).

  Specifically, the material allocation calculation unit 104 obtains the information on the number of parts with excess line by the same process as S122 in FIG. That is, the material allocation calculation unit 104 acquires an allocated production plan from the production plan information 133 in the storage unit 130. Further, the material allocation calculation unit 104 acquires the component configuration of the model of the allocated production plan from the component configuration master 132 of the storage unit 130. In addition, the material allocation calculation unit 104 acquires inventory information for all acquired components from the inventory information 134 in the storage unit 130. Then, the material allocation calculation unit 104 creates line excess component number information from the acquired information and registers it in the line excess component number information 135 of the storage unit 130.

  Here, as a method for calculating the number of excessive line parts included in the excessive line number information 135, the material allocation calculating unit 104 multiplies the number of parts for each part number in the part configuration master 132 and the planned number of production plan information 133. Calculate the production requirement of the allocated plan. In other words, the material allocation calculation unit 104 manages the necessary number for each production line / system / part number by managing the production plan in association with each system. Next, the material allocation calculation unit 104 calculates the number of stocks for each production line / system / part number from the stock information included in the stock information 134. Then, the material allocation calculation unit 104 creates line excess part number information for each production line, system, and part number, assuming that the quantity obtained by subtracting the necessary number from the above inventory number is the number of excess line parts. The number information 135 is updated. As described above, the material allocation calculation unit 104 calculates the number of excess line parts as in the example illustrated in FIG.

  Note that the material allocation calculation unit 104 may acquire the line excess component number information 135 updated by the system setting unit 103 instead of updating the line excess component number information 135.

  Then, the material allocation calculation unit 104 acquires the component configuration of the unallocated new plan, and calculates the necessary production number and the picking amount (S143).

  Specifically, the material allocation calculation unit 104 acquires the unallocated new plan set in S103 of FIG. 8 from the production plan information 133 stored in the storage unit 130, and also from the part configuration master 132 Acquire the part configuration of the model of the unallocated new plan. Then, the material allocation calculation unit 104 calculates the necessary number of production in the unallocated plan by multiplying the number of parts of the part configuration master 132 of the unallocated new plan by the number of parts and the planned number of production plan information. In this way, the material allocation calculation unit 104 manages the necessary number for each production line / system / part part number by managing the system in association with each system of the production plan.

  Next, the material allocation calculation unit 104 calculates the picking amount. Specifically, the material allocation calculating unit 104 calculates a quantity obtained by subtracting the number of excess line parts from the necessary number for each production line / system / part part number as a picking amount.

  Then, the material allocation calculation unit 104 allocates warehouse inventory based on the calculated picking amount (S144).

  Specifically, the material allocation calculation unit 104 acquires an unallocated part whose warehouse is located from the inventory information 134 stored in the storage unit 130, and based on the calculated picking amount, Therefore, the inventory information 134 is updated with the reel ID status items corresponding to the total remaining number satisfying the picking amount as reserved.

  Further, the material allocation calculating unit 104 compares the picking amount with the unallocated part quantity of the warehouse inventory for each part product number, and determines whether there is a missing part (S145). Specifically, the material allocation calculation unit 104 determines whether or not the warehouse inventory that has been allocated in the warehouse inventory allocation process (S144) is larger than the picking amount.

  If the material allocation calculation unit 104 determines that the warehouse inventory is larger than the picking amount (“None” in S145), the process proceeds to the next S148 because there is no shortage, and the warehouse inventory exceeds the picking amount. If it is determined that there are few items (“Yes” in S145), it is a shortage, and the process proceeds to S146.

  Then, when there is a shortage (“Yes” in S145), the material allocation calculation unit 104 outputs the amount of lack of parts for each part number on a screen or a form (S146).

  Then, the material allocation calculating unit 104 receives an instruction to continue or interrupt the process (S147). Specifically, the operator who operates the material management unit 100 confirms the information output in the process of S146 and determines whether to continue or interrupt the process. The material allocation calculation unit 104 proceeds to the process of S148 when accepting the continuation of the process (“continue” in S147), and terminates the process when accepting the interruption of the process (“suspend” in S147). To do.

  The material allocation calculation unit 104 creates picking information and updates the picking information 136 when there is no shortage (“none” in S145) or when continuation of processing is accepted (“continuation” in S147). (S148).

  Specifically, the material allocation calculation unit 104 creates picking information that is information to be picked from the reel ID information that has been allocated in the process of S144, and stores it in the picking information 136 of the storage unit 130 together with the system information. sign up.

  As described above, the material allocation calculation unit 104 calculates new part information, which is information indicating a new part, using the production plan information and part configuration information in the new plan. Then, the material allocation calculation unit 104 supplies the production line from the warehouse using the new part information and the remaining part information in the system information in the new plan included in the line excess part number information after the execution of the production plan. Picking component information indicating a picking component that is a component to be calculated is calculated. The material allocation calculation unit 104 outputs missing part information when the number of picking parts indicated by the picking part information is larger than the number of warehouse parts, and when the number of picking parts is equal to or less than the number of warehouse parts, Picking information in which the same system information as the system information in the new plan is added to the warehouse part information indicating the warehouse parts is created.

<About picking (S106 in FIG. 8)>
Next, details of picking (S106 in FIG. 8) in the series of processes according to the present invention will be described based on the flowchart in FIG. FIG. 12 is a flowchart illustrating an example of processing in which the picking unit 106 performs picking work according to the embodiment of the present invention.

  As shown in the figure, the picking unit 106 receives selection of a production line to be picked and picking NO (S161). That is, the operator who operates the material management unit 100 selects a production line to be picked and a picking NO.

  Then, the picking unit 106 displays information on the part number to be picked on a PDA (Personal Digital Assistant) (S162).

  Specifically, the picking unit 106 acquires information on the picking NO that has been selected from the picking information 136 stored in the storage unit 130, and acquires inventory information based on the picking information from the inventory information 134. And the picking part 106 displays the information of the part number used as the picking object on PDA used as the portable terminal of picking work.

  Then, the picking unit 106 receives an input of a reel ID corresponding to the part number displayed on the PDA (S163).

  Specifically, the operator who operates the picking unit 106 searches for a reel from the warehouse based on the information of the part part number displayed on the PDA, and inputs the searched reel ID information to the PDA. At this time, for example, the reel is printed with the barcode information of the reel ID, the PDA has a reader for scanning the barcode, and the barcode of the reel searched by the operator is scanned with the PDA. By doing so, the reel ID is input.

  Then, the picking unit 106 determines whether or not the input reel ID is a reel to be picked (S164). If the picking unit 106 determines that the reel ID is to be picked (OK in S164), the picking unit 106 proceeds to the next process (S165), and determines that the reel ID is not a reel to be picked (S164). NG), the process returns to S163.

  When the picking unit 106 determines that the reel ID is a reel to be picked (OK in S164), the picking unit 106 updates the picking information 136 and the inventory information 134 based on the input reel ID (S165). .

  Specifically, the picking unit 106 updates the picking status item of the information of the corresponding reel ID to the “completed” item from the picking information 136, and changes the location / line / system item of the information of the corresponding reel ID of the inventory information 134. , Update each.

  Then, the picking unit 106 determines whether or not the picking of all the parts has been completed (S166). If it is determined that the picking has been completed (Y in S166), the processing is finished and the picking is completed. If it is determined that there is not (N in S166), the process returns to S162 to display the information of the next part number on the PDA.

<Summary>
As described above, in the parts management apparatus 10 according to the embodiment of the present invention, the concept of a system is set as a flow of taking over the remaining number at the end of production of parts used for production on the production line to the next production. Then, set the system as the system number for each model, and if there is the same system number when calculating the picking material for the next production plan, allocate the remaining parts and the remaining number of the production completion plan with the same system number. The calculation was made so that the missing items were released from the warehouse. In addition, when there is no same system number, it is calculated to leave all warehouses.

  As a result, it is possible to create picking information using the remaining production parts of the previous model even for non-consecutive models by managing the parts type and remaining number of production lines for each flow (system) Become. In other words, the remaining parts on site are stored separately for each system, and when creating new picking information, select the system that can minimize the time to collect the parts, and create picking information using the remaining parts. I can do it. As for on-site model switching, if the next model has a high level of diversion and the current production model, the model switching is completed by exchanging only a small difference. Also, if the next model is low in diversion with the current production model, external setup using the remaining parts of another system with high diversion is performed during production of the current production model, and model switching is performed in a batch exchange I can do it.

  Specifically, the system setting unit 103 uses the production plan information, the part configuration information, and the inventory information to create line excess part number information after execution of the production plan in which the system information is determined, and the line The system information in the new plan is determined using the excess part number information. For this reason, the parts management apparatus 10 can determine the system information in the new plan by using the information stored in the storage unit 130, and uses the determined system information for the production line. Productivity can be improved by instructing the operator to move parts appropriately.

  Further, the material allocation calculating unit 104 calculates the picking part information indicating the picking part by using the production plan information, the part configuration information, and the line excess part number information in the new plan, and calculates the number of picking parts and the number of warehouse parts. And picking information in which system information is added to warehouse part information. As described above, the component management apparatus 10 can create picking information to which system information is assigned by using information stored in the storage unit 130, and picks an operator using the created picking information. Can be instructed. For this reason, productivity can be improved by instruct | indicating to a worker the appropriate movement of components with respect to a production line.

  Further, the parts management apparatus 10 creates inventory information in which predetermined system information is added to warehouse part information indicating a predetermined warehouse part based on the picking record. Thereby, inventory information can be managed for every system | strain, and productivity can be improved by instruct | indicating an operator to the appropriate movement of components with respect to a production line using the said inventory information.

  From the above, according to the component management apparatus 10 according to the embodiment of the present invention, it is possible to realize both the reduction of the component supply time and the improvement of the productivity due to the reduction of the model switching time.

  In particular, the present invention is effective in the case of producing a variety of products on a single production line in small-volume production.

  Further, since the production can be performed without wondering whether the worker only supplies parts or switches the model, there is no difference between workers and production can be performed without wasted time.

<Notes>
In the above embodiment, one line is set as one production line for each line. However, two lines can be set as one production line for every two lines, and three lines can be set as one production line. Applicable. Furthermore, one factory can be virtually applied as one production line.

  In the above embodiment, the system determination set value (part sharing rate) is set to 0.5, but it is preferable that the system determination set value can be changed. For example, it is convenient if the setting of the system determination set value can be changed for each production line and for each period. When the worker has time, the inventory can be reduced by lowering the system determination set value and supplying each part. Conversely, when the operator has no time, the time can be used more effectively by increasing the system determination set value and exchanging parts for each carriage. Note that the change of the system setting value may be performed by an operator, or may be automatically performed by the system setting unit 103.

  Moreover, in the said embodiment, although the components management apparatus 10 was provided with each component shown by FIG. 1, the components management apparatus 10 is not provided with all the components shown by FIG. Also good. For example, the component management apparatus 10 may include only the system setting unit 103. Similarly, in FIG. 8, the component management apparatus 10 may perform only the processing (S103 in FIG. 8) performed by the system setting unit 103. Also by this, the parts management apparatus 10 can improve productivity by managing parts using the system information and instructing an operator to appropriately move the parts to the production line.

  In addition, the present invention can be realized not only as such a component management apparatus 10 but also as a component management method including steps characteristic processing performed by a processing unit included in the component management apparatus 10. Can do. Further, it can be realized as a program or an integrated circuit for causing a computer to execute characteristic processing included in the component management method. Needless to say, such a program can be distributed via a recording medium such as a CD-ROM and a transmission medium such as the Internet.

  The component management apparatus 10 according to the embodiment of the present invention has been described above, but the present invention is not limited to this embodiment. That is, the embodiment disclosed this time should be considered as illustrative in all points and not restrictive. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

  The present invention can be used as a component management device for managing components mounted on a printed circuit board, particularly as a component management device for managing components supplied to a production line according to a production plan for various printed circuit boards. it can.

DESCRIPTION OF SYMBOLS 10 Parts management apparatus 100 Material management part 101 Production plan input part 102 Picking information preparation part 103 System setting part 104 Material allocation calculation part 105 Inventory input part 106 Picking part 107 Production result input / material consumption calculation part 108 Return goods calculation part 109 Master Input unit 110 Production plan creation device 120 Production result collection device 130 Storage unit 131 Parts information master 132 Parts configuration master 133 Production plan information 134 Inventory information 135 Line excess parts number information 136 Picking information

Claims (5)

In accordance with a production plan for producing a printed circuit board, a component management device that manages components supplied to a production line using information stored in a storage unit,
The storage unit
A production plan including a plurality of the production plans and system information that is information determined for each of the production plans and is information for identifying a part group composed of the plurality of parts used in the production plan Information and
For each of the system information, line excess parts number information including remaining parts information indicating remaining parts that are parts remaining in the parts group identified by the system information after execution of the production plan;
Storing component configuration information including used component information indicating a used component that is a component used for production of the printed circuit board for each production plan;
The parts management device
The remaining parts for each system information indicated by the remaining parts information included in the remaining parts information included in the line excess parts information after execution of the production plan in which system information is determined among the plurality of production plans included in the production plan information; Using a sharing rate indicating the degree of commonality with the used parts indicated by the used part information included in the part configuration information in the new plan which is a production plan in which system information is not defined among the plurality of production plans, A component management apparatus comprising a system setting unit that determines system information indicating a group of parts used in the new plan. The storage unit
In addition to storing line inventory parts information indicating line inventory parts that are parts in stock on the production line, and inventory information including the number of line inventory parts,
The production plan information further including the type of the printed circuit board produced in the production plan, and the number of the printed circuit boards,
The line excess part number information further including the number of remaining parts for each remaining part;
Storing the used component information for each type of the printed circuit board as the used component information, and the component configuration information further including information indicating the number of used components,
The system setting unit
Using the production plan information and the component configuration information, calculate the number of used parts used in the production plan in which the system information is determined,
Using the calculated number of used parts and the inventory information, calculate the number of remaining parts after execution of the production plan in which the system information is determined, and create the line excess parts number information,
The component management apparatus according to claim 1, wherein the system information indicating a component group used in the new plan is determined using the created line excess component number information. The storage unit further stores picking information including warehouse part information indicating a warehouse part that is a part existing in a warehouse, and system information indicating a part group that supplies the warehouse part,
The parts management apparatus further includes a material allocation calculation unit that creates the picking information for picking a new part from the warehouse that is a part used in the new plan for which the system setting unit has determined system information. ,
The material allocation calculator
Using the production plan information and the part configuration information in the new plan, calculating new part information that is information indicating the new part,
Parts to be supplied from the warehouse to the production line using the new parts information and the remaining parts information in the system information in the new plan included in the line excess parts number information after the production plan is executed Calculate picking part information indicating the picking part that is
When the number of the picking parts indicated by the picking part information is larger than the number of the warehouse parts, the shortage information is output, and when the number of the picking parts is equal to or less than the number of the warehouse parts, the warehouse part is indicated. The parts management apparatus according to claim 1, wherein the picking information is created by adding the same system information as the system information in the new plan to warehouse parts information. The storage unit further stores inventory information including warehouse part information indicating a warehouse part that is a part existing in a warehouse, and system information indicating a part group that supplies the warehouse part,
The parts management device further includes:
The warehouse part information indicating the predetermined warehouse part is the same as the predetermined system information based on the picking record performed according to the picking information for supplying the predetermined warehouse part to the part group indicated by the predetermined system information. The component management apparatus according to claim 1, further comprising a picking unit that creates the inventory information to which the system information is attached. According to a production plan for producing a printed circuit board, a component management method for managing components supplied to a production line using information stored in a storage unit,
The storage unit
A production plan including a plurality of the production plans and system information that is information determined for each of the production plans and is information for identifying a part group composed of the plurality of parts used in the production plan Information and
For each of the system information, line excess parts number information including remaining parts information indicating remaining parts that are parts remaining in the parts group identified by the system information after execution of the production plan;
Storing component configuration information including used component information indicating a used component that is a component used for production of the printed circuit board for each production plan;
The component management method includes:
The remaining parts for each system information indicated by the remaining parts information included in the remaining parts information included in the line excess parts information after execution of the production plan in which system information is determined among the plurality of production plans included in the production plan information; Using a sharing rate indicating the degree of commonality with the used parts indicated by the used part information included in the part configuration information in the new plan which is a production plan in which system information is not defined among the plurality of production plans, A parts management method including a system setting step for determining system information indicating a part group used in the new plan.

Images